Textured Coated Reflector for Optical Attenuation

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Solution Overview

Problem

Existing optical communication systems face challenges in attenuating light to prevent detector saturation and signal distortion, particularly in high-transfer-rate data transmission, as current methods require additional components, mechanical complexity, and environmental sealing to maintain reflective surface integrity.

Innovation Solution

An optical block with a textured coated reflective surface that attenuates light by deliberately spoiling the reflective surface through defects, such as laser markings, and encapsulating the surface to maintain reflective properties despite environmental contaminants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If an optical attenuator is used in the optical path, then light attenuation is achieved, but device complexity and part count increase

Engineering Contradiction:

Improvelight attenuationVSAvoidpart count

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent combines the attenuation function with the existing optical block structure by texturing the total internal reflection surface. This merges the attenuation functionality into the housing itself, eliminating the need for separate attenuator components while achieving the desired light loss effect through surface texturing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces mechanical attenuators with a texturized surface that provides attenuation through optical scattering. This substitution eliminates mechanical moving parts and complex adjustment mechanisms, using instead a static textured surface that achieves attenuation through its geometric structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Loss of energy

If defocusing is used to attenuate light, then light coupling into fiber decreases, but mechanical adjustment range increases and cladding modes are excited

Engineering Contradiction:

Improvelight coupling attenuationVSAvoidmechanical adjustment range

Core Design Contradiction:

Loss of energyVSEase of operation

Solution Approach 1:

The patent replaces mechanical defocusing adjustments with a fixed texturized surface that provides attenuation. This eliminates the need for mechanical adjustment mechanisms while achieving consistent attenuation, and prevents excitation of cladding modes that occurs with defocusing methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of energy

If a TIR surface is used for attenuation, then light attenuation is achieved, but the surface must remain free of contaminants

Engineering Contradiction:

Improvelight attenuationVSAvoidcontaminant sensitivity

Core Design Contradiction:

Loss of energyVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful effect of contaminants on the TIR surface into a beneficial feature by designing the attenuation mechanism to rely on controlled texturing rather than pristine surface conditions. The texturized surface provides consistent attenuation even in the presence of contaminants, turning the previously problematic surface condition into an acceptable operating state.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Adaptability or versatility

If multiple attenuation blocks are used for multi-channel devices, then individual channel attenuation is achieved, but device complexity and cost increase

Engineering Contradiction:

Improveindividual channel attenuationVSAvoidnumber of attenuation blocks

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies different texturing patterns to different regions of the optical block's TIR surface, allowing each channel to have its own attenuation characteristics. This local differentiation of surface properties enables individual channel control without requiring separate attenuator components for each channel, reducing overall device complexity.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution allows for adjustable attenuation of light in optical fibers without adding components or increasing mechanical complexity, ensuring the reflective surface remains unaffected by liquids or contaminants, thereby maintaining optimal signal transmission.

Implementation Method 1

The coating is textured to deliberately spoil the reflective surface causing an amount of the light beam to be attenuated

Methodology Applied

Scientific EffectLight scattering: Scattering

Implementation Method 2

The coating is textured to deliberately spoil the reflective surface causing an amount of the light beam to be attenuated

Methodology Applied

Scientific EffectLight absorption: Absorption (EM radiation)

Implementation Method 3

Another known method of reducing the amount of light coupled into a fiber, disclosed in U.S. Pat. No. 10,884,198 ('198 patent) is to deliberately spoil the reflectivity of a total internal reflection (TIR) surface by texturing the surface

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Data Source

PatentUS20240302608A1Controlled attenuation of a reflection from a coated surface

Publication Date: 2024.09.12 SAMTEC INC

AI summary

An optical block includes a first surface that receives light entering the optical block, a second surface through which the light exits the optical block, and a reflector that reflects light from the first surface towards the second surface. The reflector includes a reflective surface formed by a coating which is textured to attenuate the light transmitted through the optical block. The reflective surface is encapsulated so that its reflective properties are not affected by liquids or contaminants on an outer surface of the coating.